Method and device for generatively producing at least one component area

ABSTRACT

Disclosed is a method for generatively producing or for repairing at least one area of a component, wherein a zone arranged downstream of a molten bath is post-heated to a post-heating temperature and the component is set to a base temperature, and also a device for carrying out such a method.

The invention relates to a method for generatively producing at leastone area of a component according to the preamble of patent claim 1 andto an apparatus for carrying out such a method according to the preambleof patent claim 7.

A method and an apparatus for generatively producing a component aredisclosed, for example, in German patent DE 196 49 865 C1. The componentis made up of individual powder layers which are each fixed to thepreceding powder layer by means of a laser beam guided in accordancewith a cross-sectional geometry of a component model. In the case ofalloys which are not suitable for fusion welding, such as Mar M247,however, the high local temperature gradient between the molten bath andadjoining component areas can lead to hot cracking.

DE 10 2007 059 865 A1 proposes, for example for setting stress profiles,post-treating the powder layer by means of the introduction of heatafter the melting or after the solidification of the melt. Materialcharacteristics such as hardness, toughness or strength and also thematerial behavior can thereby be locally influenced in a targetedmanner.

Patent application WO 2008/071165 A1, in the name of the applicant,proposes reducing the hot cracking by global heating of the component inthe area of the powder layer to be produced. This effect can only beachieved, however, in the case of a relatively low feed rate.

It is also known for the component to be preheated by means of inductionin the powder bed. This has the disadvantage that it may lead to aninhomogeneous temperature distribution in the case of complex componentgeometries, even despite adaptation of the induction coil geometry. Thishas negative effects on the component quality.

It is an object of the invention to provide a method for generativelyproducing at least one area of a component which eliminates theaforementioned disadvantages and prevents or at least greatly reduceshot cracking particularly in the case of a high feed rate, and also anapparatus for carrying out such a method.

This object is achieved by a method having the steps of patent claim 1and by an apparatus having the features of patent claim 7.

In a method according to the invention for generatively producing atleast one area of a component which is made up of individual powderlayers, the powder layer to be produced is heated locally to a meltingtemperature by means of a first high-energy beam and a molten bath isformed. According to the invention, a zone arranged downstream of themolten bath is post-heated to a post-heating temperature by means of asecond high-energy beam, and the component is set globally to a basetemperature by means of a heating device. The solution according to theinvention adapts the temperature downstream of the molten bath to themelting temperature, such that only a small temperature gradient ispresent in the component area of the molten bath and therefore hotcracking is prevented. Since the melting temperature is very high,however (in the case of Mar M247, it is 1300° C. to 1400° C., forexample), the component which forms is additionally preheated to a basetemperature or to a base temperature level according to the invention.The powder deposited on the component is thereby preheated to atemperature close to the melting temperature, as a result of which theheating of the powder to the melting temperature can be temporallyshortened and therefore the feed rate can be increased.

In one exemplary embodiment, the base temperature is set at a constanttemperature level, preferably in a range of between 300° C. and 400° C.below the melting temperature. Given a melting temperature of between1300° C. and 1400° C., the base temperature is therefore preferablyapproximately 900° C. to 1100° C.

To uniformly set the temperature of the component, it is advantageous ifenergy is introduced into the component from as many sides as possibleand the latter is therefore heated over its entire surface area orvirtually over its entire surface area.

In a preferred exemplary embodiment, the component is heatedinductively, which makes particularly quick and targeted heatingpossible.

In one exemplary embodiment, the downstream zone is formed adjoining themolten bath. Steep changes in temperature between the molten bath andthe post-heating zone and therefore unnecessary loading of the powderlayer to be produced are thereby avoided.

In order to prevent an environment of the heating device from beingheated, the latter can be cooled by way of a cooling device delimitingits environment, for example.

An apparatus according to the invention for carrying out a method asclaimed in one of the preceding claims has a first radiation source foremitting a high-energy beam, for example a laser beam or an electronbeam, which can be moved in relation to the area of a component to beproduced generatively, for locally heating a powder layer to be producedto a melting temperature for producing a molten bath. According to theinvention, provision is made of a second radiation source for emitting asecond high-energy beam, for example a laser beam, an electron beam oran IR beam, which can be moved in relation to the component area, forpost-heating a zone arranged downstream of the molten bath to apost-heating temperature, and of a heating device for setting thecomponent globally to a base temperature.

In a preferred exemplary embodiment, the heating device is in the formof an induction coil which delimits a heating chamber for receiving thecomponent. An alternating current flows through the induction coil, as aresult of which a magnetic field forms, this bringing about eddycurrents in the component which are converted into Joule heat.

It is preferable for a cooling device to be provided for cooling anenvironment surrounding the heating device.

In order to obtain the greatest possible flexibility with respect to thefeed direction, the radiation sources can be operated as the otherrespective radiation source.

Other advantageous exemplary embodiments of the invention are thesubject of further dependent claims.

Preferred exemplary embodiments of the invention will be explained inmore detail hereinbelow with reference to greatly simplified schematicillustrations, in which:

FIG. 1 shows a cross-sectional view of an apparatus according to theinvention,

FIG. 2 shows a plan view of a component area to be produced, and

FIG. 3 shows a cross section through the component area shown in FIG. 2.

As shown in the simplified illustration in FIG. 1, an apparatus 1according to the invention for generatively producing, in particular forrepairing or reconstructing, an area of a component 2, for example arotor blade of an aircraft engine, by forming a multiplicity of powderlayers 4 a, 4 b, 4 c arranged one above another (see FIG. 2) has amounting 6 for receiving the component 2, a lifting table 8 for loweringthe component 2 in the vertical direction z, a heating device 10 forsetting the component 2 to a base temperature T1, and two radiationsources 12, 14 for emitting in each case a high-energy beam 16, 18 inthe direction of the component 2 for fixing and solidifying and forlocally post-heating the powder layer 4 a, 4 b, 4 c produced last ineach case.

The mounting 6 is in the form of a pillar, which is supported with afoot portion 20 on the lifting table 8 and, with a head portion 22,defines a receptacle 24 for fixing the component 2 during processing.

The lifting table 8 is mounted in an installation space 26 of theapparatus 1 so as to be movable in the vertical direction z and, aftereach powder layer application, is lowered by a layer thickness of thesubsequent powder layer 4 a, 4 b, 4 c.

The heating device 10 is in the form of a liquid-cooled induction coil.It has a coil 28, through which current can flow and between the coilthreads of which there is arranged a coolant duct 30. It defines aradially closed heating chamber 32, in which the component 2 is arrangedand which has such a height that the component 2 is positioned in theheating chamber 32 throughout the processing process. The component 2 isheated to the base temperature T1 and kept at this temperatureconstantly by means of the heating device 10. The base temperature T1 orthe set temperature level is dependent on material and is, for examplein the case of the alloy Mar M247, approximately 900° C. to 1100° C. Thebase temperature T1 is preferably approximately 300° C. to 400° C. belowa preferred melting temperature T2 of the respective alloy or of thepowder.

The radiation sources 12, 14 are preferably lasers emitting laser beams16, 18, in particular solid-state lasers such as Nd:YAG with awavelength of λ=1064 nm, the beam guidance of which is explained in moredetail in FIGS. 2 and 3.

Furthermore, the apparatus 1 has a housing 34 inserted into theinstallation space 26 and a cooling device 36. The housing 34 isarranged above the lifting table 8 and is supported on the edge 38 of aside wall 40 of the apparatus 1 which delimits the installation space26. It is split into two with an inner wall 42 and an outer wall 44,which delimit an annular space 46 for receiving the cooling device 36.The cooling device 36 serves in particular for avoiding a lateralenvironment 48 surrounding the heating device 10.

Furthermore, the apparatus 1 has an outer cover 50 for closing off theinstallation space 26 at the end outside the heating device 10, whichcover is inserted in a recess 52 in the inner wall 42 and extendsradially in relation to the heating device 10. Similarly, provision ismade of an inner end cover 54, which closes off the heating chamber 32in the axial direction and defines a working plane for building up thepowder layers 4 a, 4 b, 4 c.

For feeding the powder to form the powder layers 4 a, 4 b, 4 c in thearea of the component 2 in the working plane, the apparatus 1 has asupply device (not shown). In addition, the apparatus 1 has a slide (notshown) guided over the inner cover 50 for forming the powder layers 4 a,4 b, 4 c and also for setting the layer thicknesses thereof. The powderis preferably selected from a group consisting ofhigh-temperature-resistant alloys which are not suitable for fusionwelding, for example Mar M247, and has a preferred particle size with adiameter d<63 μm. In addition, it can be gas-atomized with a high finescontent.

As shown in FIGS. 2 and 3, which show a method step 3 according to theinvention for producing the component area, the powder layers 4 a, 4 b,4 c, as indicated by the arrows, are produced by an alternating relativelinear movement or feed direction in the x direction between the laserbeams 16, 18 and the component 2. To realize this alternating ordirection-changing movement, the lasers 12, 14 can be operated as theother respective laser 14, 12. The laser beams 14, 16 in this respectpreferably each have such a focusing that the diameter thereofcorresponds to the width of the component area to be produced.

The laser beams 16, 18 are each directed at a local zone 56, 58 of thecomponent 2 which are arranged in succession in the feed direction. Thezones 56, 58 can be of the same size and are arranged adjoining oneanother. As viewed in the feed direction, the powder is heated to themelting temperature T2 in the front or first zone 56 by means of thefirst laser beam 16. The rear or second zone 58 is heated to apost-heating temperature T3 by means of the second laser beam 18. Themelting temperature T2 is dependent on material and/or is, in the caseof the high-temperature-resistant alloy such as Mar M247, approximately1300° C. to 1400° C. The post-heating temperature T3 is likewisedependent on material and/or dependent on location (for compensating foran inhomogeneous temperature distribution in complex componentgeometries), but is greater than the base temperature T1, such that thefollowing relationship applies: T2>T3>T1. To build up the componentarea, the latter is set to the base temperature T1 in its powder bed byway of the heating device 10. The applied powder layer 4 c is likewiseheated to the base temperature T1 as it is being deposited. Then, thelasers 12, 14 are actuated and guided over the powder layer 4 c insuccession in the feed direction. The powder in the front zone 56 isheated to the melting temperature T2 by way of the front laser beam 16,melted and fixed to the previously produced powder layer 4 b. The powderwhich has just been fixed then passes through the post-heating zone 58,in which it is set by way of the rear laser beam 18 to the post-heatingtemperature T3, which is lower than the melting temperature T2 buthigher than the base temperature T1. After it has left the post-heatingzone, the powder cools to the base temperature T1, which corresponds tothe general component temperature during processing. The temperatureprofile or the temperature gradient between the molten bath 56 and thefollowing component zone is therefore harmonized, or the temperaturegradient proceeding from the molten bath 56 via the post-heating zone 58to the following component area is balanced. Furthermore, the preheatingof the component 2 to the base temperature T1 brings about a relativelysmall necessary rise in temperature of the powder supplied to thecomponent 2 for heating to the melting temperature T2.

Disclosed is a method for generatively producing or for repairing atleast one area of a component, in which a zone arranged downstream of amolten bath is post-heated to a post-heating temperature and thecomponent is set to a base temperature, and also an apparatus forcarrying out such a method.

LIST OF REFERENCE SIGNS

-   1 Apparatus-   2 Component-   4 a, b, c Powder layer-   6 Mounting-   8 Lifting table-   10 Heating device-   12 Radiation source-   14 Radiation source-   16 High-energy beam-   18 High-energy beam-   20 Foot portion-   22 Head portion-   24 Receptacle-   26 Installation space-   28 a, b, c Coil thread-   30 Coolant duct-   32 Heating chamber-   34 Housing-   36 Cooling device-   38 Edge-   40 Side wall-   42 Inner wall-   44 Outer wall-   46 Inner space-   48 Environment-   50 Outer cover-   52 Recess-   54 Inner cover-   56 Molten bath-   58 Post-heating zone-   T1 Base temperature-   T2 Melting temperature-   T3 Post-heating temperature

1.-10. (canceled)
 11. A method for generatively producing of forrepairing at least one area of a component which is made up ofindividual powder layers, wherein the method comprises (i) locallyheating, by a first high-energy beam, a powder layer to be produced to amelting temperature (T2), whereby a molten bath is formed, (ii)post-heating, by a second high-energy beam, a zone arranged downstreamof the molten bath to a post-heating temperature (T3), and (iii)setting, by a heating device, a temperature of the component globally toa base temperature (T1).
 12. The method of claim 11, wherein the basetemperature (T1) is kept at a constant level.
 13. The method of claim12, wherein the base temperature (T1) is kept in a range of between 300°C. and 400° C. below the melting temperature (T2).
 14. The method ofclaim 11, wherein the component is heated virtually uniformly over itsentire surface area.
 15. The method of claim 14, wherein the componentis heated inductively.
 16. The method of claim 11, wherein the zonearranged downstream of the molten bath adjoins the molten bath.
 17. Themethod of claim 11, wherein an environment surrounding the heatingdevice is cooled.
 18. The method of claim 11, wherein the firsthigh-energy beam is a laser beam.
 19. The method of claim 11, whereinthe first high-energy beam is an electron beam.
 20. The method of claim11, wherein the second high-energy beam is a laser beam.
 21. The methodof claim 11, wherein the second high-energy beam is an electron beam.22. The method of claim 11, wherein the second high-energy beam is an IRbeam.
 23. An apparatus for carrying out the method of claim 11, whereinthe apparatus comprises (a) a first radiation source for emitting thefirst high-energy beam, which is movable in relation to an area of thecomponent to be produced generatively or to be repaired, to locally heatthe powder layer to be produced to a melting temperature (T2) forproducing the molten bath, (b) a second radiation source for emittingthe second high-energy beam, which is movable in relation to thecomponent, for post-heating the zone arranged downstream of the moltenbath to a post-heating temperature (T3), and (c) a heating device forsetting the component globally to a base temperature (T1).
 24. Theapparatus of claim 23, wherein the heating device (c) is an inductioncoil which delimits a heating chamber for receiving the component. 25.The apparatus of claim 23, wherein the apparatus further comprises acooling device for cooling an environment surrounding the heating device(c).
 26. The apparatus of claim 23, wherein the first radiation source(a) can be operated as the second radiation source (b) and vice versa.27. The apparatus of claim 23, wherein the first high-energy beam is alaser beam.
 28. The apparatus of claim 23, wherein the first high-energybeam is an electron beam.
 29. The apparatus of claim 23, wherein thesecond high-energy beam is a laser beam.
 30. The apparatus of claim 23,wherein the second high-energy beam is an electron beam.